Spill resistant carpet backing

ABSTRACT

An aqueous dispersed polymeric composition for preparing the spill resistant carpet backing is provided. The aqueous dispersed polymeric composition of the present invention comprises an aqueous dispersed polymeric material, an inorganic filler, and a hydrophobic compound selected from the group consisting of a hydrophobic acid, a salt of a hydrophobic acid, and mixtures thereof. Alternatively, the inorganic filler is pretreated with the hydrophobic compound. Also, a kit and a method for preparing a spill resistant carpet backing from the aqueous dispersed polymeric composition is provided.

This application claims the benefit of U.S. Provisional ApplicationSerial No. 60/096,777 filed Aug. 17, 1998.

FIELD OF THE INVENTION

This invention relates to a spill resistant carpet backing. Moreparticularly, it relates to using a hydrophobic acid-treated inorganicfiller or salts thereof as part of an aqueous dispersed polymericcomposition to increase the spill resistance of a carpet backing.

DESCRIPTION OF THE PRIOR ART

Generally, tufted carpets minimally consist of tufted fibers through aprimary backing and a precoat. Tufted carpets have a precoat and mayalso have additional layers such as a laminate layer, a secondary layer,and a foam layer. Moreover, the tufted carpet may have more than onesecondary layer. The tufted carpet may be applied to a variety ofsubfloors, including wood, concrete, and tile.

The precoat is required to anchor the carpet tufts to the primarybacking. It may also contain an adhesive to adhere the tufted carpet toadditional layers or the subfloor. The precoat can affect the carpet'stuft bind, hand, delaminating properties, wet strength properties, wearresistance, and barrier performance. Alternatively, a laminate layer maybe applied without a precoat and anchor the carpet tufts to the primarybacking. But, better anchoring is achieved when a precoat is appliedthan with a laminate layer is applied alone.

The precoat may be prepared from several materials. However, it isusually prepared from a polyurethane material or a styrene-butadienelatex. It may be prepared from a butadiene-acrylonitrile latex, anethylene-vinyl acetate latex, a styrene-butadiene-butyl acrylate latex,a chloroprene latex, a polyethylene copolymer latex, an ethylene-styrenelatex, a styrene-butadiene-vinylidene chloride latex, a styrene-alkylacrylate latex, a vinyl latex, or an acrylic latex.

With regard to a polyurethane precoat, conventional practice in thecarpet manufacturing industry requires that the precoat be prepared froman isocyanate formulation (A-side formulation) and a polyol formulation(B-side formulation) at the carpet manufacturing site. This is sometimesreferred to as “A+B chemistry”. Preparing a polyurethane precoat by A+Bchemistry can result in unpredictable loss of production andinefficiency due to problems that can occur in carrying out the reactionat the manufacturing site, such as premature gellation.

Alternatively, the polyurethane precoat may be applied as an aqueouspolyurethane (PU) dispersion. Aqueous PU dispersions can be prepared bypolymerizing the polyurethane reactants in an organic solvent followedby dispersion of the resulting solution in water, and optionallyfollowed by removal of organic solvent. See U.S. Pat. Nos. 3,437,624;4,092,286; 4,237,264; 4,742,095; 4,857,565; 4,879,322; 5,037,864; and5,221,710, which are incorporated herein by reference. Also, an aqueouspolyurethane dispersion may be prepared by first forming a prepolymer,next dispersing the prepolymer in water, and finally conducting a chainextension in the water as disclosed in WO 98/41552, published Sep. 24,1998, which is incorporated herein by reference. Preparations of aqueousdispersions of polyurethane are also described in U.S. patentapplication Ser. Nos. 09/039,978 and 09/039,976. U.S. Pat. No. 4,296,159to Jenkines, et al., discloses preparing a tufted or woven articlehaving a unitary backing prepared by applying a polyurethane formingcomposition to the underside of the tufted or woven article.

The precoat may consist of an aqueous styrene butadiene latex.Styrene-butadiene (SB) latexes for use in carpet are described, forexample, in P. L. Fitzgerald, “Integral Latex Foam Carpet Cushioning”,J. Coat Fab. 1977, Vol. 7 (pp.107-120); and in R. P. Brentin, “LatexCoating Systems for Carpet Backing”, J. Coat. Fab. 1982, Vol. 12 (pp.82-91). SB latexes provide flexibility in production costs owing to theability to include low to high concentrations of filler component in alow viscosity latex. However, SB latexes with filer may not, meet therigorous standards set for intermediate grade carpets. In addition,current technology may require that a latex material remain stable for aperiod of up to one year. High solids content affects the stability ofSB latexes. Accordingly, commercially available SB latexes typically donot have a solids content of greater than 55%.

Without regard to the type of material used to make the precoat, aliquid spill can detrimentally affect the carpet's performance andappearance. The liquid can flow through the precoat and then onto, or beabsorbed by, the underside of the carpet. In particular, spilled liquidssuch as beverage drinks, food, blood, urine, and feces can penetrate tothe underside of the carpet or into the subfloor so that the liquids canbe inaccessible by various cleaning methods.

When the precoat is an aqueous polymeric dispersion, variousconventional methods are used to provide a moisture or spill resistantbarrier between the primary backing and other layers or the subfloor.The conventional methods include (1) modifying the precoat formulation,(2) adding an essentially impermeable membrane between the precoat andthe other layers or the subfloor, and (3) applying a spill resistantcoating onto the precoat or another layer.

An example of an attempt to improve spill resistance by modifying theprecoat formulation is increasing the coating weight of the dispersion.This method is undesirable because it requires more material, which isexpensive. It can also yield a final carpet having undesirable hand orstiffness properties. Moreover, the precoat has an increased probabilityof blistering in the drying ovens.

Another example of an attempt to improve spill resistance by modifyingthe precoat formulation is adding a wax filler to the dispersion. Whilethe addition of waxes to aqueous styrene-butadiene latexes is known toimprove the water barrier properties of the precoat, it is also knownthat wax additives are generally detrimental to other carpet properties.

Another example of a formulation modification is the reduction of fillerlevels. But, this formulation change increases the carpet cost and mayincrease the tendency of the precoat to blister in the drying ovens.

Examples of an attempt to improve spill resistance by adding anessentially impermeable membrane between the precoat and the otherlayers or the subfloor are described in U.S. Pat. Nos. 4,336,089 and5,763,040. In U.S. Pat. No. 4,336,089; the patentees describe awater-impervious film that collects the spilled liquid below the carpetsurface. In U.S. Pat. No. 5,763,040, the patentees describe applying anon-permeable fabric or film to a carpet backing. This secondary backingprevents liquid flow to subsequent layer or to the subfloor.Unfortunately, both described membranes may permit the spilled liquid tocollect at a depth between the carpet and the underlay barrier such thatthe spilled liquid cannot be removed through traditional cleaningmethods.

An example of an attempt to improve spill resistance by applying a spillresistant coating is applying a fluorochemical or another material ontothe precoat or another layer. U.S. Pat. No. 5,348,785 describes applyinga fluorochemical on the underside of a secondary backing. The use offluorochemicals to impart water impermeability is also described in U.S.Pat. Nos. 4,619,853 and 4,643,930. Unfortunately, the use offluorochemicals can increase the cost of the carpet. Additionally, steamor extraction cleaning of a carpet can leach the fluorochemicals out ofthe carpet.

Other materials that are applied as a spill resistant coating includesilicone-based compositions, wax emulsions, naturally occurring oils,and hydrophobic acrylate resins. Applying these various hydrophobiccompositions to a secondary backing is described in U.S. Pat. No.5,558,916, but these compositions do not prevent absorption of spilledliquids by underlying layers.

It would be desirable to prepare a carpet backing that resistspenetration by spilled liquids. It would also be desirable to preparethe carpet backing by a process that would not significantly increasethe cost of manufacturing the carpet. Further, it would be desirable toprepare a spill resistant carpet backing that can protect the undersideof a carpet from spills such that the spilled liquids would beaccessible for removal by various cleaning methods.

SUMMARY OF THE INVENTION

According to the present invention, a spill resistant carpet backing isprovided. More specifically, an aqueous dispersed polymeric compositionfor preparing the spill resistant carpet backing is provided

In the preferred embodiment, the aqueous dispersed polymeric compositionof the present invention comprises an aqueous dispersed polymericmaterial, an inorganic filler, and a hydrophobic compound selected fromthe group consisting of a hydrophobic acid, a salt of a hydrophobicacid, and mixtures thereof. Alternatively, the inorganic filler ispretreated with the hydrophobic compound. Also, a kit and a method forpreparing a spill resistant carpet backing from the aqueous dispersedpolymeric composition is provided. While the most significant impact onspill resistance is achieved through using the aqueous dispersedpolymeric composition as a precoat, the aqueous dispersed compositionmay be applied as a laminate layer or a foam layer to improve spillresistance.

DESCRIPTION OF THE INVENTION

In the preferred embodiment of the present invention, the aqueousdispersed polymeric composition comprises an aqueous dispersed polymericmaterial, an inorganic filler, and a hydrophobic compound selected fromthe group consisting of a hydrophobic acid, a salt of a hydrophobicacid, and mixtures thereof. The aqueous dispersed polymeric material isselected from the group consisting of a polyurethane dispersion, astyrene-butadiene latex, a butadiene-acrylonitrile latex, anethylene-vinyl acetate latex, a styrene-butadiene-butyl acrylate latex,a chloroprene latex, a polyethylene copolymer latex, an ethylene-styrenelatex, a styrene-butadiene-vinylidene chloride latex, a styrene-alkylacrylate latex, a vinyl latex, an acrylic latex, and mixtures thereof.The preferred aqueous dispersed polymeric composition is a polyurethanedispersion.

In the present invention, polyurethane can refer to a polyurethanecompound, a polyurea compound, or mixtures thereof A polyurethanecompound can be obtained by the reaction of a polyol with apolyisocyanate. A polyurea compound can be obtained by the reaction ofan amine with a polyisocyanate. A polyurethane compound or polyureacompound can contain both urea and urethane functionality, depending onwhat compounds are included in the A and/or aside formulations. For thepurposes of the present application, no further distinction will be madeherein between the polyurethane compounds and polyurea compounds. Theterm “polyurethane” will be used generically to describe a polyurethanecompound, a polyurea compound, and mixtures thereof.

A polyurethane dispersion composition useful in the practice of thepresent invention includes water, and a polymeric compound selected fromthe group consisting of a polyurethane compound, a mixture ofpolyurethane-forming compounds, and mixtures thereof. A polyurethanedispersion as described herein can include chain extenders, surfactants,fillers, dispersants, foam stabilizers, thickeners, fire retardants,defoamers, and other materials useful in polyurethane formulations.

Polyurethane-forming compounds as used in the present invention arecompounds that are capable of forming polyurethane polymers.Polyurethane-forming compounds include, for example, polyurethaneprepolymers. Prepolymers useful in the practice of the present inventionare prepared by the reaction of active hydrogen compounds with anyamount of isocyanate in excess material relative to active hydrogenmaterial. The isocyanate functionality can be present in an amount offrom about 0.2 wt % to about 40 wt %. A suitable prepolymer can have amolecular weight in the range of from about 100 to about 10,000.Prepolymers useful in the practice of the present invention should besubstantially liquid under the conditions of dispersion.

Active hydrogen compounds can be described as compounds havingfunctional groups that contain at least one hydrogen atom bondeddirectly to an electronegative atom such as nitrogen, oxygen or sulfur.Suitable active hydrogen compounds can be polyols of molecular weight ofless than about 6000.

When the polymeric material is a polyurethane compound, the aqueousdispersed polymeric composition can include a chain extender. A chainextender is used herein to build the molecular weight of thepolyurethane prepolymer by reaction of the chain extender with theisocyanate functionality in the polyurethane prepolymer, i.e., chainextend, the polyurethane prepolymer. A suitable chain extender istypically a low equivalent weight active hydrogen containing compound,having about 2 or more active hydrogen groups per molecule. The activehydrogen groups can be hydroxyl, mercaptyl, or amino groups. An aminechain extender can be blocked, encapsulated, or otherwise rendered lessreactive. Other materials, particularly water, can function to extendchain length and so are chain extenders for purposes of the presentinvention. Polyamines are preferred chain extenders. It is particularlypreferred that the chain extender be selected from the group consistingof amine terminated polyethers such as, for example, Jeffamine D400 fromHuntsman Chemical Company, amino ethyl piperazine, 2-methyl piperazine,1,5-diamino-3-methyl-pentane, isophorone diamine, ethylene diamine,diethylene triamine, triethylene tetramine, triethylene pentamine,ethanol amine, lysine in any of its stereoisomeric forms and saltsthereof, hexane diamine, hydrazine and piperazine. In the practice ofthe present invention, the chain extender is often used as a solution ofchain extender in water.

Small amounts of chain extender can be advantageously used. Generally,the chain extender is employed at a level sufficient to react with fromabout zero (0) to about 100 percent of the isocyanate functionalitypresent in the prepolymer, based on one equivalent of isocyanatereacting with one equivalent of chain extender. It can be desirable,under certain conditions, to allow water to act as a chain extender andreact with some or all of the isocyanate functionality present

A catalyst can be used to promote the reaction between a chain extenderand an isocyanate. Suitable catalysts include tertiary amines,organometallic compounds, similar compounds, and mixtures thereof. Forexample, suitable catalysts include di-n-butyl tin bis(mercaptoaceticacid isooctyl ester), dimethyltin dilaurate, dibutyltin dilaurate,dibutyltin sulfide, stannous octoate, lead octoate, ferricacetylacetonate, bismuth carboxylates, triethylenediamine, N-methylmorpholine, similar compounds, and mixtures thereof. An amount ofcatalyst is advantageously employed such that a relatively rapid cure toa tack-free state can be obtained. If an organometallic catalyst isemployed, such a cure can be obtained by using from about 0.01 to about0.5 parts per 100 parts of the polyurethane-forming composition, byweight. If a tertiary amine catalyst is employed, the catalystpreferably provides a suitable cure using from about 0.01 to about 3parts of tertiary amine catalyst per 100 parts of thepolyurethane-forming composition, by weight. Both an amine type catalystand an organometallic catalyst can be employed in combination.

The present invention can include other filler materials. The fillermaterial can include conventional fillers such as milled glass, calciumcarbonate, aluminum trihydrate, talc, bentonite, antimony trioxide,kaolin, fly ash, or other known fillers. A suitable filler loading in apolyurethane dispersion can be from about 100 to about 1000 parts offiller per 100 parts of the polyurethane compound. Preferably, thefiller material can be loaded in an amount of at least about 200 pph(phr), more preferably at least about 300 pph, most preferably at leastabout 400 pph.

The present invention can include a filler wetting agent. A fillerwetting agent generally renders the filler material compatible with apolyurethane-forming composition. Useful wetting agents includephosphate salts such as sodium hexametaphosphate. A filler wetting agentcan be included in a polyurethane-forming composition of the presentinvention at a concentration of at least about 0.5 parts per 100 partsof filler, by weight

The present invention can include other components, such as surfactants,blowing agents, frothing agents, defoamers, fire retardants, pigments,antistatic agents, reinforcing fibers, antioxidants, preservatives, acidscavengers, and the like. Useful surfactants include cationic andanionic surfactants. Examples of anionic surfactants include sulfonates,carboxylates, and phosphates. Examples of cationic surfactants includequaternary amines.

Surfactants can be either external or internal. External surfactants aresurfactants are not chemically reacted into the polymer duringdispersion preparation. Internal surfactants are chemically reacted intothe polymer during dispersion preparation. A surfactant can be includedin an amount ranging from about 0.01 to about 20 parts per 100 parts byweight of polyurethane component.

Examples of suitable blowing agents are gases such as air, carbondioxide, nitrogen, argon, and helium; liquids such as water and volatilehalogenated alkanes; and azo-blowing agents such as azobis(formamide).Volatile halogenated alkanes include the various chlorofluoromethanesand chlorofluoroethanes. The use of a gas as a blowing or frothing agentis preferred. Particularly preferable is the use of air as a blowing orfrothing agent. A frothing agent can differ from a blowing agent in thatfrothing agents are typically introduced by mechanical introduction of agas into a liquid to froth the polymeric composition.

A polyurethane dispersion of the present invention can be stored forlater application to the back of a carpet. Storage for this purposerequires that the dispersion be storage-stable. Alternatively, thepolyurethane dispersion can be applied in a continuous manner to theback of a carpet primary backing. That is, the dispersion can be appliedto the back of a carpet as the dispersion is obtained. Polyurethanedispersions applied to a carpet in a continuous manner are not requiredto be storage-stable, and can have higher solids content and/or largermean particle size than typical storage-stable polyurethane dispersionformulations.

A suitable storage-stable polyurethane dispersion as defined herein isany polyurethane dispersion having a mean particle size of less thanabout 5 microns; a more preferable mean particle size is less than about1 micron. A polyurethane dispersion that is not storage-stable can havea mean particle size of greater than 5 microns. For example, a suitabledispersion can be prepared by mixing a polyurethane prepolymer withwater and dispersing the prepolymer in the water using a commercialblender. Alternatively, a suitable dispersion can be prepared by feedinga prepolymer into a static mixing device along with water, anddispersing the water and prepolymer in the static mixer. Continuousmethods for preparing aqueous dispersions of polyurethane are known andcan be used in the practice of the present invention. For example, U.S.Pat. Nos. 3,437,624; 4,092,286; 4,237,264; 4,742,095; 4,857,565;4,879,322; 5,037,864; and 5,221,710 describe continuous processes usefulfor obtaining aqueous polyurethane dispersions. In addition, acontinuous process for preparing an aqueous polyurethane dispersionhaving a high internal phase ratio is described in U.S. Pat. No.5,539,021, incorporated herein by reference.

The steps used in preparing a polyurethane carpet backing can be carriedout in a continuous manner. For example, the prepolymer can be preparedfrom a suitable active hydrogen-containing compound in a continuousmanner. The prepolymer can be loaded directly into a mixing device withwater to obtain an aqueous dispersion. Ultimately, the aqueouspolyurethane dispersion can be applied to a carpet primary backing in acontinuous manner to obtain a polyurethane-backed carpet

In preparing polyurethane-backed carpets according to the presentinvention, an aqueous polyurethane dispersion is applied as a layer ofpreferably uniform thickness onto one surface of a carpet primarybacking. Aqueous polyurethane dispersions of the present invention canbe applied as a precoat, a laminate layer, or a foam layer. Polyurethaneprecoats, laminate layers, and foam layers can be prepared by methodsknown in the art. Precoats, laminate layers and foam layers preparedfrom latexes are described in P. L. Fitzgerald, “Integral Latex FoamCarpet Cushioning”, J. Coat Fab. 1977, Vol. 7 (pp. 107-120), and in R.P. Brentin, “Latex Coating Systems for Carpet Backing”, J. Coat. Fab.1982, Vol. 12 (pp. 82-91). In preparing a frothed polyurethane backing(frothing), it is preferred to mix all components and then blend a gasinto the mixture, using equipment such as an Oakes or Firestone foamer.

The polyurethane-forming composition can be applied to one surface of acarpet primary backing before it cures to a tack-free state.Alternatively, a polyurethane dispersion containing no unreactedisocyanate functionality can be applied, thereby removing the need tocure the polymer. Typically the polyurethane-forming composition isapplied to the surface attached to a primary backing.

The composition may be applied and gauged to the carpet primary backingusing equipment such as a doctor knife, air knife, or extruder.Alternatively, the composition may be applied by (1) forming it into alayer on a moving belt or other suitable apparatus, (2) dehydrating orpartially curing, and (3) finally, marrying it to the carpet primarybacking. It may be married to the carpet primary backing with equipmentsuch as a double belt laminator (also known as double band) or a movingbelt with an applied foam cushion.

The amount of polyurethane-forming composition used can vary widely,from about 5 to about 500 ounces per square yard, depending on thecharacteristics of the textile. After the layer is applied and gauged,water is removed from the dispersion and the layer can be cured usingheat from any suitable heat source such as an infrared oven, aconvection oven, or heating plates.

A styrene-butadiene latex useful for practicing the present invention isdisclosed in P. L. Fitzgerald, “Integral Latex Foam Carpet Cushioning”,J. Coat. Fab. 1977, Vol. 7 (pp. 107-120) and in R. P. Brentin, “LatexCoating Systems for Carpet Backing”, J. Coat. Fab. 1982, Vol. 12 (pp.82-91), both incorporated herein by reference. Astyrene-butadiene-vinylidene chloride latex useful for practicing thepresent invention is disclosed in U.S. Pat. No. 5,741,393, incorporatedherein by reference.

U.S. Pat. No. 5,770,660, incorporated herein by reference, discloses amethod for preparing a butadiene-acrylonitrile latex that is useful forpracticing the present invention. U.S. Pat. Nos. 3,644,262 and4,164,489, incorporated herein by reference, disclose methods forpreparing ethylene-vinyl-acetate latexes that are useful for practicingthe present invention. U.S. Pat. No. 5,591,806, incorporated herein byreference, discloses a method for preparing an ethylene acrylic acidaqueous dispersion that is useful for practicing the present invention.

U.S. Pat. Nos. 3,890,261 and 5,661,205, incorporated herein byreference, disclose methods for preparing chloroprene latexes useful forpracticing the present invention. U.S. Pat. No. 5,380,785, incorporatedherein by reference, discloses a method for preparing a butylacrylate-acrylonitrile-styrene latex that is useful for practicing thepresent invention. U.S. Pat. Nos. 4,689,256 and 5,300,551, incorporatedherein by reference, disclose methods for preparing vinyl chloridepolymer latexes that are useful in practicing the present invention.

U.S. Pat. No. 5,591,806, incorporated herein by reference, discloses amethod for preparing a ethylene acrylic acid copolymer latex that isuseful in practicing the present invention. U.S. Pat. No. 4,714,728,incorporated herein by reference, discloses a method for preparing anaqueous dispersion of acidic ethylene interpolymers that are useful inpracticing the present invention.

U.S. Pat. No. 4,228,058, incorporated herein by reference, discloses amethod for preparing a mixture of vinylidene chloride latex and astyrene-butadiene latex useful in practicing the present invention.Other methods of preparing useful aqueous dispersed polymericcompositions would be readily apparent to a person of ordinary skill inthe art in view of this disclosure. Those methods and aqueous dispersedpolymeric compositions are within the scope of the invention with regardto preparing useful aqueous dispersed polymeric compositions.

The inorganic fillers of the present invention include calciumcarbonate, calcium sulfate, kaolin, lignite fly ash, silica, talc,feldspar, mica, glass spheres, wollastonite, aluminum trihydrate,aluminum oxide, fiber glass, similar compounds, and mixtures thereof. Inthe present invention, the preferred inorganic filler is calciumcarbonate.

The hydrophobic acids and salts of hydrophobic acid for treating theinorganic filler mixtures of the present invention include C4 to C22acids and salts thereof. Also, the acids can be saturated orunsaturated. Examples of such acids include, but are not limited to,butyric acid, hexanoic acid, octanoic acid, decanoic acid, dodecanoicacid, lauric acid, myristic acid, palmitic acid, oleic acid, linoleicacid, stearic acid, linolenic acid, similar compounds, and mixturesthereof. In the present invention, the preferred acid-treated inorganicfiller is stearic acid-treated calcium carbonate.

The salts of any of the hydrophobic acids described herein, alone or inadmixture with any other salt or hydrophobic acid, can be useful in thepractice of the present invention. Preferably, the salt is selected fromthe group consisting of calcium stearate, lithium stearate, and zincstearate, and more preferably, zinc stearate, and most preferable,wettable zinc stearate. Wettable zinc stearate is easily and uniformlycompounded with a polyurethane dispersion and yields superior spillresistance. The preferred inorganic filler and hydrophobic saltcombination is calcium carbonate with zinc stearate.

Other useful hydrophobic acids or hydrophobic acid salts include gumrosin, wood rosin, tall oil rosin, abietic acid, oxidized polyethylenecontaining carboxylic acid groups, ethylene-acrylic acid copolymers,ethylene-methacrylic acid copolymers, polyolefins grafted, withunsaturated carboxylic acids, polyolefins grafted with anhydrides suchas maleic anhydride, methacrylic acid, maleic acid, fumaric acid,acrylic acid, and the like.

The hydrophobic acid or a salt thereof can be added to the carpetbacking formulation mixture in an amount of from about 0.025% weight byweight (w/w) to about 10% (w/w), based on the total weight of solidspresent in the mixture. Preferably the hydrophobic acid or its salt isadded in an amount of from about 0.5% (w/w) to about 6.0% (w/w), morepreferably form about 1.0% (w/w) to about 3.0% (w/w) most preferablyfrom about 1.0% (w/w) to about 2.0% (w/w), based on total solids.

The inorganic filler can also be surface treated with the hydrophobicacid or its salt prior to introduction into the carpet backingdispersion formulation. This may be accomplished in a variety of ways.For example, the hydrophobic acid may be surface coated onto the fillerin a high intensity mixer above the melting point of the hydrophobicacid. Another method involves the spraying of the aqueous dissolved ordispersed hydrophobic acid or its salt onto the agitated filler.

In an alternate embodiment, the aqueous dispersed polymeric compositioncomprises an aqueous dispersed polymeric material and a treatedinorganic filler, having been treated with a hydrophobic compoundselected from the group consisting of a hydrophobic acid, a salt of ahydrophobic acid, and mixtures thereof.

In another alternate embodiment of the present invention, a kit forpreparing a spill resistant carpet backing is provided. It comprises anaqueous dispersed polymeric material, an inorganic filler, and ahydrophobic compound selected from the group consisting of a hydrophobicacid, a salt of a hydrophobic acid, and mixtures thereof. Alternatively,the kit can comprise an aqueous dispersed polymeric material and atreated inorganic filler, having been treated with a hydrophobiccompound selected from the group consisting of a hydrophobic acid, asalt of a hydrophobic acid, and mixtures thereof.

The present invention also provides a method for preparing a spillresistant carpet backing comprising (a) mixing an inorganic filler withan aqueous dispersed polymeric material and (b) admixing a hydrophobiccompound selected from the group consisting of a hydrophobic acid, asalt of a hydrophobic acid, and mixtures thereof. Alternatively, themethod can comprise (a) treating an inorganic filler with a hydrophobiccompound selected from the group consisting of a hydrophobic acid, asalt of a hydrophobic acid, and mixtures thereof and (b) mixing thetreated inorganic filler with an aqueous dispersed polymeric material.

EXAMPLES

The following examples merely exemplify various embodiments of theinvention. It is understood that the following examples are provided tofurther illustrate the invention. They do not in anyway limit the scopeof the present invention.

Table of Compounds

The following compounds were used in the preparation of the exemplifieddispersions. The table provides the compound's generic name, its trademark name, and its vendor.

Generic Name Trade Mark Vendor ethylene oxide capped VORANOL ™ The Dowpolypropylene oxide diol, 5287 Polyol Chemical 2000 molecular weightCompany 50:50 mixture of 2,4′- ISONATE ™ The Dowdiisocyanatodiphenylmethane and 50 MDI Chemical4,4′-diisocyanatodiphenylmethane Company 25:75 mixture of 2,4′-ISONATE ™ The Dow diisocyanatodiphenylmethane and 25 OP MDI Chemical4,4′-diisocyanatodiphenylmethane Company Dispersing surfactant DeSulfDBS-60T Deforest Enterprises Inc. Hydrocarbon-based defoamer Nopco NDWHenkel Corp. Silicon-based aqueous dispersions DC 85 Dow Corning CorpCalcium carbonate Georgia Georgia Marble Marble #8 Co. Stearic acidtreated Georgia Georgia Marble calcium carbonate Marble CS11 Co. Aqueousethylene acrylic Michem P4983-40R Michem acid dispersion Liquid ammoniumSTANFAX 320 Parachem stearate (33%) Southern Inc. Zinc stearatedispersion Synpro Zincloid ™ Ferro Chemical Co. Zinc stearate Synpro ZnFerro Chemical stearate GP Co. Zinc stearate Synpro Zn Ferro Chemicalstearate wettable Co. Zinc stearate Synpro Zn Ferro Chemical stearateS-1058 Co.

Aqueous Polyurethane Dispersion Preparation

For Example Nos. 1 and 13-23, a prepolymer was prepared by reacting63.35 percent by weight (% w/w) VORANOL™ 5287 polyol, 33.3% w/wISONATE™50 MDI, 1.35% w/w diethylene glycol, and 2.00% w/w polyethyleneoxide monol having a molecular weight of 950. Example Nos. 2-6 usedISONATE™ 25 OP MDI for the precoat layer instead., of ISONATE™ 50 MDI;the laminate layer was prepared with ISONATE™ 50 MDI. Example Nos. 13-18were prepared with 1.63 parts per hundred resin of Paragum™ 241. ExampleNos. 24 and 25 were prepared with a secondary backing. All layers wereprepared with 5 parts per hundred of Nopco NDW.

The remaining steps were conducted at an ambient temperature of 19° C.

The prepolymer was fed continuously at a rate of 32.1 gallons/minute(121.5 liters/minute) through a first arm fitted to a first T. DeSulfDBS-60T surfactant was fed at a rate of 1.61 gallons/minute (6.09liters/minute) through a first arm of a second T and merged with a waterstream flowing at a rate of 5.5 gallons/minute (20.8 liters/minute)through the second arm of the second T. The prepolymer stream and thewater/surfactant stream were merged at the first T and passed through astatic mixer.

Next, they were fed to the input port of a IKA-SD 41 Super-Dispax™dispersing instrument (a trademark of Ika Works, Inc.). The IKA-SD 41Super-Dispax™ dispersing instrument is a rotor/stator device, which wasoperated at 1200 rpm. The ratio of feeds into the dispersing instrumentwas 81.9% prepolymer, 4.1% surfactant solution, and 14.0% water.

A high internal phase ratio (HIPR) emulsion formed in the dispersinginstrument. It had a volume average particle size of 0.285 microns and apolydispersity of 3.1 as measured by a Coulter LS130 particle sizeanalyzer.

The HIPR emulsion from the dispersing instrument was fed into a firstarm attached to a third T and merged with an aqueous stream fed througha second arm of the third T at the rate of 5.1 gallons/minute (19.3liters/minute). The output of the combined streams was fed into one armof a fourth T that was attached to the input of a Lightnin™ model 0.25LB in-line blender (a trademark of Greey/Lightnin).

Chain extension was accomplished in the in-line blender by concurrentlypumping a. 10% aqueous piperazine solution through the other arm of thefourth T. The piperazine solution was added at a constant rate of 18.0gallons/minute (68.1 liters/minute) (0.75 equivalents based on theisocyanate groups of the prepolymer). The two streams were mixed in thein-line blender operating at 1500 rpm.

The product was collected and allowed to stand overnight to allow thewater to react with the react with the remaining isocyanate groups. Theresulting stable poly(urethane/urea) dispersion was found to have asolids content of 56.0% by weight and a volume average particle size of0.256 microns and a polydispersity of 3.5 as measured by a Coulter LS230 particle size analyzer.

Example No. 7—Styrene-Butadiene Latex Preparation

A styrene-butadiene latex test sample was substituted in thepolyurethane dispersion formulations. The latex contained approximatelyfifty-percent solids.

British Spill Test Carpet Coating Sample Preparation

The British Spill Test Carpet Coating samples were prepared using thefollowing method. First, a carpet sample was stretched onto a frame.Next, the carpet was held in place on a tandem roll coater. A permanentmarker was used to mark off an 11″×14″ (28 cm×35.6 cm) area on thecarpet.

The amount of precoat and laminate to achieve the desired coat weightwas determined using the following calculation:

a) Calculate area to cover (yd²)=length*width=11″*14″=154 in²*(1yd²/1296 in²)=0.119 yd²(0.099 m²);

b) Target DRY 38 oz/yd²(900.7 g/m²) 80% precoat−30.4 oz/yd²(720.5 g/m²)20% laminate=7.6 oz/yd²(180.1 g/m²);

c) Target WET 30.4 oz/yd²(730.5 g/m²)/0.762 solids=39.9 oz/yd²(945.6g/m²) 7.6 oz/yd²(180.1 g/m²)/0.762 solids=9.60 oz/yd²(227.5 g/m²);

d) For precoat, convert oz to grams (39.9 oz/yd²)(11b/16 oz)(454g/11b)=1132 g/yd² (945.6 g/m²);

e) Use calculated coverage area to give grams needed (1132 g/yd²)*0.119yd²=134.7 g;

f) Add 20 g to account for coverage on the jumbo roller; and

g) Repeat steps d-f for the laminate coat and add only an additional 10grams for jumbo roller coverage.

The roller was placed such that its milled gap and side bars were at thetop of the carpet The precoat was poured and distributed evenly in frontof the roller. Without applying any pressure, the ends of the rollerwere held and rolled to the permanent mark at the end of the carpet. Thejumbo roller with two side weights was rolled from the bottom up anddown two times.

The laminate was weighed out. The roller without the milled gap wasplaced at the top of the carpet. The laminate was poured and distributedevenly in front of the roller. Without applying any pressure, the endsof the roller were held and dragged to the permanent mark at the end ofthe carpet.

The carpet was then clipped in place at the edges of the frame andimmediately placed into a 400° F. (204° C.) oven until the pyrometerread a temperature of 265° F. (129° C.) on the carpet. The carpet wasthen removed from the oven and allowed to cool to room temperature.After the carpet was cooled, it was removed from the frame and placed ina controlled environment to equilibrate.

Example Nos. 24 and 25—Carpets with Secondary Backing Preparation

The secondary backing carpet Example Nos. 24 and 25 were prepared usingthe following method. First, a carpet sample was held down at its topand bottom edges to a Plexiglas surface. Next, a permanent marker wasused to mark off an 11″×15″ (28 cm×38.1 cm) area on the carpet.

The amount of precoat and laminate to achieve the desired coat weightwas determined using the following calculation:

a) Calculate area to cover (yd²)=length *width=11″*15″=165 in²*(1yd²/1296 in²)=0.127 yd²(0.106 m²);

b) Target DRY 44 oz/yd²(1042.8 g/m²) 80% precoat−35.2 oz/yd²(834.2 g/m²)20% laminate=8.8 oz/yd²(208.6 g/m);

c) Target WET 35.2 oz/yd²(834.2 g/m²) /0.762 solids=46.2 oz/yd²(1094.9g/m²) 8.8 oz/yd²(208.6 g/m²)/0.762 solids=11.1 oz/yd²(263.1 g/m²);

d) For precoat, convert oz to grams (46.2 oz/yd²)(11b/16 oz)(454g/11b)=1311 g/yd² (1096 g/m²);

e) Use calculated coverage area to give grams needed (1311 g/yd²)*0.127yd=166.5 g;

f) Add 20 g to account for coverage on the jumbo roller; and

g) Repeat steps d-f for the laminate coat and add only an additional 10grams for jumbo roller coverage.

The roller was placed such that its milled gap and side bars were at thetop of the carpet. The precoat was weighed out The precoat was pouredand distributed evenly in front of the roller. Without applying anypressure, the ends of the roller were held and rolled to the permanentmark at the end of the carpet. The jumbo roller with two side weightswas rolled from the bottom up and down two times.

The laminate was weighed out. The roller without the milled gap wasplaced at the top of the carpet. The laminate was poured and distributedevenly in front of the roller. Without applying any pressure, the endsof the roller were held and dragged to the permanent mark at the end ofthe carpet.

A drawdown box with its 25 mm side down was placed on a second piece ofPlexiglas. The drawdown box was filled to ¾ full with evenly distributedprecoat. With a downward pressure, the drawdown box was used to put afilm of the compound onto the second piece of Plexiglas.

A piece of secondary backing was cut to the size of the carpet andplaced on top of the film. A roller was rolled over the backing to theend of the glass. The secondary backing was removed from the glass andplaced over the coated area of the carpet such that coated area of thebacking faced the coated area of the carpet.

The carpet and the secondary backing were held together with a weight attheir top edge. The coatings were married together with a roller.

The carpet and the secondary backing were placed into a 275° F. (135°C.) oven until the pyrometer read a temperature of 265° F. (129° C.) onthe carpet. The carpet was then removed from the oven and placed in acontrolled environment to equilibrate.

Production Scale Example Nos. 8-12

A 3300-pound (1497 kg) batch of the precoat compound and a 3200-pound(1451 kg) batch of the laminate compound were prepared using standardcompound mixing equipment. The finishing range consisted of a dualdirector applicator and a scrim pan-roll coater. The direct coaters wereset up to split the precoat and laminate coatings to a desired 80-20distribution.

A first roll coater had a six inch (15.2 cm) diameter and ran at 30+rpm. The second roll coater had an eight inch (20.3 cm) diameter and wasmaintained stationary. The adhesive pan was as small as practical forthe roll coater and auxiliary edge coater rolls.

The tufted carpet fibers through the primary backing was coated facedown with the precoat roller speed set at the speed of the carpet andweight set at normal production rates. The laminate roller was fixed andgapped. A lick roll coater that positioned directly in the adhesive panwas used to apply the precoat. The wet coating wet distribution was 40opsy (ounces per square yard) (948 g/m²) precoat, 10 opsy (237 g/m²)laminate coat, and 8 opsy (1.90 g/m²) adhesive coat After marrying, thecarpet with its face up was dried in a 400° F. (204° C.) oven.

Tables 1-4

Table 1 contains the formulation properties for Example Nos. 1-33. Table1 also identifies the additives and inorganic fillers, if any, and theamounts added in parts per hundred resin.

Table 2 contains the physical properties of Example Nos. 1-7. ExampleNos. 16 contained 200 pph filler loads in the laminate layers withnon-treated calcium carbonate. Example 4 also contained 25% stearicacid-treated calcium carbonate filler in the precoat But, all failed theBritish Spill test.

Table 3 contains physical testing data for Example Nos. 8-12. ExampleNos. 8-10 were non-treated calcium carbonate carpet samples, and ExampleNos. 11-12 were prepared with stearic acid-treated calcium carbonate.The laminate layers contained 200 pph filler loads. All of thenon-treated carpet samples failed the British Spill test while both ofthe acid-treated samples passed.

Table 4 contains physical testing data for Example Nos. 13-33. ExampleNo. 13 was prepared with ammonium stearate. Example Nos. 14-18 wereprepared with calcium stearate; Example Nos. 19, 24, 26, and 32 wereprepared with an ammonium stearate/calcium carbonate combination; andExample Nos. 20-23, 25, 27-31, and 33 were prepared with a zincstearate/calcium carbonate combination. Example No. 13 passed theBritish Spill test. While Example No. 14 had no bleed through, it had awatermark. Example Nos. 15-18 passed the British Spill test. ExampleNos. 14-18 demonstrate that calcium stearate generally provides goodspill resistance as measured by the British Spill test

Example Nos. 19, 24, 26, and 32 passed the British Spill test, but eachhad a watermark. Example Nos. 19, 24, 26, and 32 demonstrate thatammonium stearate provides good spill resistance as measured by theBritish Spill test Similarly, Example Nos. 20-23, 25, 27-31, and 33passed the British Spill test, but Example Nos. 2-23, 27-28, and 30-31had a watermark. Significantly, Example Nos. 30 and 31 only demonstrateda small watermark after 5 hrs and Example No. 33 did not show awatermark. Example Nos. 20-23, 25, 27-31, and 33 illustrate that thecombination of zinc stearate and calcium carbonate provides spillresistance as measured by the British Spill test:

TABLE 1 Example # 1 2 3 4 5 6 7 Precoat - Properties Filler Load 150 150150 150 150 150 150 AFV¹, #3 @ 20 rpm, cps N/A N/A N/A N/A N/A N/A N/AAF cup wt, g/3 oz. (g/85 g) N/A N/A N/A N/A N/A N/A N/A Compound Visc.(#5 @ 20 rpm), cps 16500 N/A N/A N/A N/A N/A 12980 Compound Cup wt, g/3oz. (g/85 g) 123.6 N/A N/A N/A N/A N/A N/A Additives ATH² None ATH 25%MP³ 5% None CS11 DC85 Coat Visc. (#5 @ 20 rpm), cps 16340 10460 1230012020 N/A 16100 13420 Coating Cup wt, g/3 oz. (g/85 g) 126.1 132.3 118.6108.6 N/A 129 126.3 Coat weight, oz/yd² (g/m²) 41.7 39.2 38.1 N/A 39.938.2 (988) (929) (903) (946) (905) Laminate Coat - Properties FillerLoad 200 200 200 200 200 200 200 Filler GM 8⁴ GM 8 GM 8 GM 8 GM 8 GM 8GM 8 Filler Description CaCO₃ CaCO₃ CaCO₃ CaCO₃ CaCO₃ CaCO₃ CaCO₃Compound Visc. (#5 @ 20 rpm), cps 18800 19300 19300 19300 19300 1930031450 Compound Cup wt, g/3 oz. (g/85 g) N/A N/A N/A N/A N/A N/A N/AAdditives None None None None None None None Coat Visc. (#5 @ 20 rpm),cps 21800 21800 N/A N/A N/A N/A 29500 Coating Cup wt, g/3 oz. (g/85 g)131.4 131.4 N/A N/A N/A N/A 131.4 Example # 8 9 10 11 12 Precoat -Properties Filler Load 150 150 200 200 200 Additives Coat Visc. (#5 @ 20rpm), cps 10360 10360 22350 28000 28000 Coating Cup wt, g/3 oz. (g/85 g)124.5 124.5 140.2 143.1 143.1 Laminate Coat - Properties Filler Load 200200 200 200 200 Filler GM 8 GM 8 GM 8 CS11 CS11 Filler Description CaCO₃CaCO₃ CaCO₃ Acid Acid CaCO₃ CaCO₃ Additives Coat Visc. (#5 @ 20 rpm),cps 18050 18050 22350 28000 28000 Coating Cup wt, g/3 oz. (g/85 g) 137.9137.9 140.2 143.1 143.1 ¹AFV = after filler viscosity; ²ATH = aluminumtrihydrate; ³MP = Michem P4983-40R; ⁴GM 8 = Georgia Marble #8 Calciumcarbonate

Example # 13 14 15 16 17 18 19 20 Laminate Coat - Properties Filler Load(Total) 200 200 200 200 200 200 200 200 Filler None Ca Ca Ca Ca Ca NH₄ZsD⁹/ Stearate Stearate Stearate Stearate Stearate Stearate/ GM 8 GM 8Filler Load (Ca Stearate) 0 1.0 1.0 2.0 5.0 10.0 Filler Load (Stearate0.75/0 0/1.0 Compound - NH₄/Zn) Additives STANFAX ™ NH₄ Stearate .75phr⁵ Coat Visc. (#5 @ 20 rpm), cps 23350 20200 22150 22700 24250 2570021350 16780 Coating Cup wt, g/3 oz. (g/85 g) 125.79 129.60 132.00 139.50134.50 126.70 134.39 129.66 Coating weight, g/3 oz (g/85 g) 42.60 40.71Example # 21 22 23 24 25 26 27 28 Laminate Coat - Properties Filler Load(Total) 200 200 200 200 200 200 200 200 Filler ZsG¹⁰/ ZsW¹¹/ ZsS¹²/ NH₄ZsW/ NH₄ ZsW/ ZsW/ GM 8 GM 8 GM 8 Stearate/ GM 8 Stearate/ GM 8 GM 8 GM8 GM 8 Filler Load (Ca Stearate) Filler Load (Stearate 0/5.0 0/5.0 0/5.00.75/0 0/5 0.75/0 0/1.0 0/3.5 Compound - NH₄/Zn) Additives Coat Visc.(#5 @ 20 rpm), cps 20100 20300 20250 21350 20300 20450 2240 23200Coating Cup wt, g/3 oz. (g/85 g) 139.26 134.16 129.30 134.39 134.16 129139.4 135.5 Coating weight, g/3 oz (g/85 g) 43.04 45.06 42.53 50.4550.71 40.08 43.15 Example # 29 30 31 32 33 Laminate Coat - PropertiesFiller Load (Total) 200 200 200 200 200 Filler ZsW/ ZsW/ ZsW/ NH₄ ZsG/GM 8 GM 8 GM 8 Stearate/ GM 8 GM 8 Filler Load (Ca Stearate) Filler Load(Stearate 0/5.0 0/10.0 0/20.0 0.75/0 0/5.0 Compound - NH₄/Zn) AdditivesCoat Visc. (#5 @ 20 rpm), cps 20650 21050 25900 24500 20550 Coating Cupwt, g/3 oz. (g/85 g) 133.1 132.1 130.3 137.37 129.9 Coating weight, g/3oz (g/85 g) 41.40 40.87 40.98 44.81 42.12 ⁵phr = parts per hundred resin⁹ZsD = Zinc stearate dispersion; ¹⁰ZsG = Zinc stearate GP; ¹¹ZsW = Zincstearate wettable; ¹²Zinc stearate S-1058

TABLE 2 Tuft Tuft Delam. Delam. Edge Bind Bind (Wet (Wet Ravel Tuft (Wet(Wet Delam. 1 Min) 4 hr) Edge (Wet Bind 20 min) 4 hr) (lb/in)/ (lb/in)/(lb/in)/ Ravel 4 hr) Ex.# (lb/kg) (lb/kg) % R. (lb/kg) (kg/cm) (kg/cm) %R. (kg/cm) (lb/kg) (lb/kg) British Spill 1 Fail @ 400° F. (204° C.) 2 2011.1 6.9 62.2 Fail @ 400° F. (9.08) (1.98) (1.23) (204° C.) 3 22 11.27.2 64.3 Fail @ 400° F. (9.99) (1.99) (1.28) (204° C.) 4 19.6 11.9 9.781.5 Slight Fail @ (8.90) (2.12) (1.73) 400° F. (204° C.) 5 Fail @ 400°F. (204° C.) 6 20.2 11.3 7.4 65.5 Fail @ 400° F. (9.17) (2.01) (1.32)(204° C.) 7 20.4 10.8 9.6 88.9 np @ 400° F. (9.26) (1.92) (1.71) (204°C.), Blistered R. = Retention; Delam. = Delamination; PH = Pinhole; wm =Watermark; Swm = Slight Watermark VSwm = Very Slight Watermark; SM =Smudge; No BT = No Bleed Through; np = Near Pass

TABLE 3 Tuft Tuft Delam. Delam. Edge Bind Bind (Wet (Wet Ravel Tuft (Wet(Wet Delam. 1 Min) 4 hr) Edge (Wet Bind 20 min) 4 hr) (lb/in)/ (lb/in)/(lb/in)/ Ravel 4 hr) Ex.# (lb/kg) (lb/kg) % R. (lb/kg) (kg/cm) (kg/cm) %R. (kg/cm) (lb/kg) (lb/kg) British Spill 8 22.8 9 9.7 4.1 4.7 1.4 Fail(10.4) (4.09) (1.73) (0.73) (2.13) (0.64) 9 20.8 9.1 9.7 4 4 1.2 Fail(9.44) (4.13) (1.73) (0.71) (1.82) (0.54) 10 21.3 8.7 9.1 4 3.8 0.9 Fail(9.67) (3.95) (1.62) (0.71) (1.73) (0.41) 11 23.1 10.4 14.1 7.8 4.8 1.7Pass (10.5) (4.72) (2.51) (1.39) (2.18) (0.77) 12 18.2 9 11.9 6.3 4.51.4 Pass (8.26) (4.09) (2.12) (1.12) (2.04) (0.64) R. = Retention;Delam. = Delamination; PH = Pinhole; wm = Watermark; Swm = SlightWatermark VSwm = Very Slight Watermark; SM = Smudge; No BT = No BleedThrough; np = Near Pass

TABLE 4 Tuft Tuft Delam. Delam. Edge Bind Bind (Wet (Wet Ravel Tuft (Wet(Wet Delam. 1 Min) 4 hr) Edge (Wet Bind 20 min) 4 hr) (lb/in)/ (lb/in)/(lb/in)/ Ravel 4 hr) Ex.# (lb/kg) (lb/kg) % R. (lb/kg) (kg/cm) (kg/cm) %R. (kg/cm) (lb/kg) (lb/kg) British Spill 13 15.9 6.7 Pass (7.22) (3.04)14 19.1 6.8 No BT, wm (8.67) (3.09) 15 18.7 7.7 Pass (8.49) (3.50) 1617.2 7.8 Pass (7.81) (3.54) 17 18.8 8.6 Pass (8.53) (3.90) 18 18.3 9.8Pass (8.31) (4.45) 19 17.5 6.6 38.0 Pass, wm (7.95) (3.00) 20 16.4 4.930.0 Pass, wm (7.44) (2.22) 21 16.2 7.4 45.7 Pass, VSwm (7.35) (3.36) 2216.0 7.9 49.3 Pass, VSwm (7.26) (3.59) 23 16.5 7.7 46.8 Pass, VSwm(7.49) (3.50) 24 18.4 9.3 50.5 Pass (8.35) (4.22) 25 19.6 14.0 71.5 Pass(8.90) (6.36) 26 17.2 7.1 41.2 Pass, wm (7.81) (3.22) 27 20.5 8.1 39.6Pass, wm (9.31) (3.68) 28 20.0 7.4 36.9 Pass, wm (9.08) (3.36) 29 17.09.0 52.9 Pass (7.72) (4.09) 30 18.7 8.0 42.9 Pass, Swm @ 5 hrs (8.49)(3.63) 31 19.0 8.5 45.0 Pass, Swm @ 5 hrs (8.63) (3.86) 32 18.0 7.9 44.2Pass, wm (8.17) (3.59) 33 16.5 10.3 62.1 Pass (7.49) (4.68) R. =Retention; Delam. = Delamination; PH = Pinhole; wm = Watermark; Swm =Slight Watermark VSwm = Very Slight Watermark; SM = Smudge; No BT = NoBleed Through; np = Near Pass

The embodiments described herein are given to illustrate the scope andspirit of the present invention. The embodiments herein will makeapparent to those skilled in the art other embodiments that may also beused. These other embodiments are within the scope of the presentinvention. Thus, the scope of the invention should be determined by theappended claims and their legal equivalents, rather than by theembodiments given herein.

What is claimed is:
 1. An aqueous dispersed polymeric composition forpreparing a spill resistant carpet backing comprising: a. an aqueouspolyurethane dispersion; b. an inorganic filler; and c. a hydrophobicsalt of a hydrophobic acid, wherein the hydrophobic acid is selectedfrom the group consisting of butyric acid, hexanoic acid, octanoic acid,decanoic acid, dodecanoic acid, lauric acid, myristic acid, palmiticacid, oleic acid, linoleic acid, stearic acid, linolenic acid, gumrosin, wood rosin, tall oil rosin, abietic acid, oxidized polyethylenecontaining carboxylic acid groups, ethylene-acrylic acid copolymers,ethylene-methacrylic acid copolymers, polyolefins grafted withunsaturated carboxylic acids, polyolefins grafted with anhydrides,methacrylic acid, maleic acid, fumaric acid, acrylic acid and mixturesthereof.
 2. The aqueous dispersed polymeric composition of claim 1,wherein the inorganic filler is treated with the hydrophobic salt priorto formation of the aqueous dispersed polymeric composition.
 3. Theaqueous dispersed polymeric composition of claim 1, wherein theinorganic filler is selected from the group consisting of calciumcarbonate, calcium sulfate, kaolin, lignite fly ash, silica, talc,feldspar, mica, glass spheres, wollastonite, aluminum trihydrate,aluminum oxide, fiber glass, and mixtures thereof.
 4. The aqueousdispersed polymeric composition of claim 3, wherein the hydrophobic saltof the hydrophobic acid has a cation that is lithium, calcium, zinc or acombination thereof.
 5. The aqueous dispersed polymeric composition ofclaim 4, wherein the cation is calcium, zinc or combination thereof. 6.The aqueous dispersed polymeric composition of claim 5 wherein thehydrophobic salt is calcium stearate, zinc stearate or combinationthereof.
 7. The aqueous dispersed polymeric composition of claim 6,wherein the hydrophobic salt is zinc stearate.
 8. The aqueous dispersedpolymeric composition of claim 7, wherein the zinc stearate is wettable.9. An aqueous dispersed polymeric composition for preparing a spillresistant carpet backing comprising: a. an aqueous dispersed material;b. an inorganic filler; and c. a hydrophobic salt of a hydrophobic acid.10. The aqueous dispersed polymeric composition of claim 9, wherein theaqueous dispersed polymeric material is a polyurethane dispersion. 11.The aqueous dispersed polymeric composition of claim 9, wherein theinorganic filler has thereon a coating of the hydrophobic salt.
 12. Theaqueous dispersed polymeric composition of claim 9, wherein the aqueousdispersed polymeric material is selected from the group consisting of apolyurethane dispersion, a styrene-butadiene latex, abutadiene-acrylonitrile latex, an ethylene-vinyl acetate latex, astyrene-butadiene-butyl acrylate latex, a chloroprene latex, apolyethylene copolymer latex, an ethylene-styrene latex, astyrene-butadiene-vinylidene chloride latex, a styrene-alkyl acrylatelatex, a vinyl latex, an acrylic latex, and mixtures thereof.
 13. Theaqueous dispersed polymeric composition of claim 9, wherein theinorganic filler is selected from the group consisting of calciumcarbonate, calcium sulfate, kaolin, lignite fly ash, silica, talc,feldspar, mica, glass spheres, wollastonite, aluminum trihydrate,aluminum oxide, fiber glass, and mixtures thereof.
 14. The aqueousdispersed polymeric composition of claim 9, wherein the hydrophobic saltof the hydrophobic acid has a cation that is lithium, calcium, zinc orcombination thereof.
 15. The aqueous dispersed polymeric composition ofclaim 14, wherein the cation is calcium, zinc or combination thereof.16. The aqueous dispersed polymeric composition of claim 9, wherein thehydrophobic salt is calcium stearate, zinc stearate or combinationthereof.
 17. The aqueous dispersed polymeric composition of claim 16,wherein the hydrophobic salt is zinc stearate.
 18. The aqueous dispersedpolymeric composition of claim 17 wherein the hydrophobic salt iswettable zinc stearate.
 19. The aqueous dispersed polymeric compositionof claim 9, wherein the hydrophobic acid is selected from the groupconsisting of butyric acid, hexanoic acid, octanoic acid, decanoic acid,dodecanoic acid, lauric acid, myristic acid, palmitic acid, oleic acid,linoleic acid, stearic acid, linolenic acid, gum rosin, wood rosin, talloil rosin, abietic acid, oxidized polyethylene containing carboxylicacid groups, ethylene-acrylic acid copolymers, ethylene-methacrylic acidcopolymers, polyolefins grafted with unsaturated carboxylic acids,polyolefins grafted with anhydrides, methacrylic acid, maleic acid,fumaric acid, acrylic acid, and mixtures thereof.
 20. A spill resistantcarpet backing prepared using the aqueous dispersed polymericcomposition of claim
 1. 21. The spill resistant carpet backing of claim20, wherein the spill resistant carpet backing is a carpet layerselected from the group consisting of a precoat, a laminate layer, and afoam layer.
 22. A spill resistant carpet backing prepared using theaqueous polymeric composition of claim
 9. 23. The spill resistant carpetbacking of claim 22, wherein the spill resistant carpet backing is acarpet layer selected from the group consisting of a precoat, a laminatelayer, and a foam layer.
 24. An aqueous dispersed polymeric compositionfor preparing a spill resistant carpet backing comprising: (a) anaqueous dispersed polymeric material; (b) an inorganic filler; and (c) ahydrophobic compound selected from the group consisting of a hydrophobicacid, a salt of a hydrophobic acid and mixtures thereof, wherein thehydrophobic compound has a melting point of at least about 120° C. 25.The aqueous dispersed polymeric composition of claim 24, wherein thehydrophobic compound is zinc stearate, calcium stearate, lithiumstearate or a combination thereof.
 26. The aqueous dispersed polymericcomposition of claim 24, wherein the melting point is at most about 212°C.